Building Partners



Building Partners
issue 18
Helping Ardo UK
keep its cool the latest edition of
Building Partners. One of
the greatest testimonials any
company can receive is in the
form of repeat business, and
in this issue we highlight our
ongoing relationship with frozen
fruit and vegetable specialist
Ardo UK, for whom we’ve recently
completed a cold store extension.
Our regular EHS feature focuses
on the new CDM Regulations
which came into force on
6 April, and we also take a look
at where the industry is heading
in 2015. As always, we’d love
to hear your feedback
– please email
[email protected]
with any suggestions or
questions you may have.
Mark Reeve,
Managing Director
Ardo UK by numbers:
After successfully completing a £6,700,000
cold store and packing hall for Ardo UK
in 2010 over a 44-week period, Chalcroft
was called upon in late 2013 to partner the
Kent-based business on the design and
build of a new extension to the facility.
Jon Barnes, Supply Chain and Inventory Director,
Ardo UK
When frozen fruit and
vegetable specialist Ardo UK
needed a new cold store
facility to cope with growing
demand, the company looked
no further than Chalcroft.
Bordered by the Kent Downs, an area of
outstanding natural beauty, as well as
residential communities, Ardo UK was keen to
minimise the impact of a new building.
With the guidance of the local council,
Chalcroft incorporated exterior cladding in
two shades to help mask the structure – pale
‘goosewing grey’ to blend in with cloudy
British skies when viewed from below, and a
darker grey to merge with surrounding trees
when seen from the hills above.
With the original premises built in 2000 and
the first extension in 2010, providing both
interior and exterior continuity between
each phase of construction was a priority for
Ardo UK and Chalcroft. Inside, the building
fabric has been carefully sealed to ensure a
consistent temperature of -22°C is achieved.
The extension was built
with efficiency in mind,
with space-saving
mobile racking and
LED lighting.
The future’s
A look back at
the 2015 BFFF
Laying the
Chalcroft builds
Skills Centre
£10,700,000 – total project value
Total site capacity now 22,500 pallets
Site now covers 9,700m²
Consistent cold store
temperature -22°C
Chalcroft also incorporated a protective
firewall between the new and existing
phases, meaning the business could remain
operational as any fire could be contained
without spreading to adjacent phases while
outside, the cladding was extended to
provide a seamless finish. In order to fulfil
customer commitments, the new build had
to be carefully planned so as not to disrupt
operations. Jon Barnes, Ardo UK’s Supply
Chain and Inventory Director, explained:
Special Projects
navigate challenging
refurbishment for
Thales UK
Construction compliance:
“Business continuity was critical and having
worked with Chalcroft on the previous phase,
we knew we could rely on them to manage
the build sensitively. Indeed, some of the team
working on the cold store had been part of the
original project and that stability contributed
greatly to a well-managed project.”
new regulations affect
building projects
Mark Reeve, MD of Chalcroft commented:
“Having the opportunity to undertake new work
for existing clients is always gratifying, and is
testament to the outstanding service we provide.
We develop close relationships with customers,
becoming a true partner to them thanks to our
understanding of not only the project, but the
ongoing needs of their business.”
Monday 6 April saw the new Construction Design
and Management (CDM) Regulations 2015 officially
come into force, marking the beginning of a sixmonth transitional period before the deadline
date of 6 October. So what do companies planning
construction projects need to know?
The new £4,000,000 cold store opened in
late 2014 and adds almost 1,900m² storage
space to Ardo UK’s portfolio, bringing the site
total to nearly 9,700m². Capable of holding 4,200
pallets, the extension was built with efficiency in
mind, with space-saving mobile racking and LED
lighting controlled with motion sensors to reduce
energy consumption. The cold store has loading
bays to accommodate double-decker trailers, as
more transport companies adopt taller trailers to
reduce their number of journeys.
Todd Hallam, EHS Director, explains.
For further information on Chalcroft’s
experience in the chill and cold storage,
logistics, food and beverage sectors,
The future’s frozen
A look back at the 2015 BFFF Conference
Left to right: Andy Weston-Webb, Birds Eye Ltd; James Walton, IGD; Andrew Kenny, Asda and Brian Young, BFFF.
As a long term supporter/member of the
British Frozen Food Federation (BFFF), we
exhibited at the most recent conference in
March, which included several interesting
talks and lively debates. ‘The Changing Face
of Retail’ was a key theme and, while it was
clear that there’s a huge opportunity for frozen
food suppliers and retailers to capitalise on
today’s food buying trends, it will require a
strong infrastructure to satisfy demand
for innovative frozen food products.
James Walton, Chief Economist at IGD,
spoke convincingly on the predicted market
changes, explaining that while frozen food
experienced an explosion in popularity in
the 1970s due to the new affordability of
freezers – and again in the 1980s as owning
a microwave became achievable – there was
no such technology on the horizon to boost
the frozen sector. However, frozen food is
undergoing a renaissance of sorts,
as consumers seek to reduce food waste,
control portion sizes and gain the health
benefits of frozen produce – meaning
change is still to come.
Asda’s Director of Frozen Foods Andrew Kenny
explained that one of the avenues Asda have
explored to compete with discounters is the
concept of Click & Collect, which few budget
supermarkets offer. With a growing trend
towards cook-from-frozen ingredients in
preference to ready meals, which reduce waste
and retain freshness for longer, Click & Collect
may well see an increase in frozen purchases.
There is every likelihood
that, in the coming years, the
supply chain for frozen food
will need to be rethought.
The notion of ‘making’ food from frozen as
distinct from ‘reheating’ a ready meal was also
a key theme of Andy Weston-Webb’s talk.
As Managing Director – UK & Ireland of Birds Eye,
he has seen first-hand how adult dining and
make-at-home frozen dishes, including
Birds Eye’s Inspirations range, have gained
in popularity as people seek convenience
without compromising on nutrition and taste.
He argued that adding more product lines
was not necessarily the way forward,
but rather differentiating through adapting
to shoppers’ changing tastes. He felt that
the improving quality of frozen foods would
actually increase revenue and volume and
allow frozen food suppliers to stay relevant.
It’s clear that the opportunity for retailers to
grow their frozen sales is real and exciting.
But is the infrastructure up to the challenge?
A growing trend towards Click & Collect or
online deliveries may mean additional cold
storage space is required, as products are
picked from freezer displays and must be
safely stored at the required temperature
with the rest of the order. And, while
shoppers increasingly shop lighter and more
often in preference to the traditional weekly
‘big shop’, stores will need to be prepared for
more frequent purchases of frozen goods –
affecting the supply chain throughout.
In order to capitalise on the frozen gold
rush, retailers and suppliers alike must
ensure their cold store network can cope
with expected demand. High-care, air and
temperature controlled storage will be crucial
in maintaining the high levels of quality
expected by today’s shoppers – eliminating
contamination and spoilage and ensuring
frozen ingredients and meals reach the fork
in optimum condition.
Brian Young, Chief Executive of the BFFF,
summarised: “There is every likelihood
that, in the coming years, the supply chain
for frozen food will need to be rethought,
due in part to the rise in popularity of Click
& Collect and home delivery. Retailers are
carefully considering how they can develop
an economical way to optimise their storage
facilities and handle increased demand for
home delivery, and so it’s beyond doubt that
significant changes to infrastructure – including
cold store and warehouse facilities will arise.”
Chalcroft has specialised in cold store
supply chain construction for more than
35 years. To find out more about our service,
and view case studies of our projects with
industry leaders such as Ardo UK,
With the role of CDM Co-ordinator now made
obsolete, clients must take an overseeing role
in their construction projects with the support
of a Principal Designer (PD), which can be an
organisation or an individual who is responsible
for the pre-construction phase and oversees
design and planning, and Principal Contractor
(PC) throughout the construction phase. These
roles must now be filled where there is more
than one contractor working on a project,
regardless of size or duration. Initially, they
must ensure the PD and PC have the necessary
skills, knowledge, experience and organisational
capability to manage health and safety risks.
Pre-construction information must be
compiled by the client and issued to both
parties, providing critical and high-risk
information which is crucial in allowing
them to ensure the relevant welfare facilities
are in place and that health & safety
arrangements are implemented with regular
reviews as the project progresses. The PD
will be responsible for developing the H&S
file in the first instance. The client must also
take reasonable steps to ensure that both
the PC and PD comply fully with all their
duties and adhere to all relevant legislation
including the Health and Safety at Work Act,
Work at Height Regulations and RIDDOR.
Health &
Client companies also now have a
responsibility to inform the HSE of larger
construction projects via an F10 form if the
project is either expected to last more than
30 days and have more than 20 workers
on site at any one time, or will exceed 500
person days in total.
For more detailed information on the changes
to the CDM Regulations and the role of the
client in the construction process, download
our factsheet from
Laying the
Chalcroft builds
Construction Skills Centre
Aimed at providing the construction
professionals of the future with a strong
foundation of core skills, building work
has begun on a £3.75m Construction Skills
Centre at the Norfolk campus of Easton
& Otley College with Chalcroft appointed
as Principal Contractor.
To officially launch this major building project,
and to celebrate the signing of a new growth
deal between government and New Anglia LEP,
our Operations Director Paul Morley was invited
to an exclusive ground breaking ceremony at
the college, along with several members of the
Chalcroft contracts team. Guest of honour was
Lord Heseltine, in his role as Chairman of the
Regional Growth Fund.
The new development, due for summer
completion, is a one storey steel frame
building with exterior cladding and brickwork
detailing. The new facility will have 1,476m²
of inside space for courses in carpentry
and bricklaying as well as electrical and
multi-skilled programmes. A further 600m²
of covered outdoor areas completes the
development. Building with sustainability
in mind, the new structure will feature
photovoltaic panels for solar energy
generation as well as a biomass boiler, and
rain water will be harvested for tool washing.
Lizzie Stratton, Contracts Manager,
explained: “We are naturally delighted to
work on a project aimed at equipping future
construction workers with essential skills.
{in brief...}
Left to right: Paul Morley, Chalcroft Operations Director,
Lord Heseltine, Mark Pendlington, Chairman of New
Anglia LEP and Christina Sadler, Interim Principal of
Easton & Otley College.
The site poses interesting challenges, from
working around the college’s animal care,
veterinary and equine science facilities and
ensuring minimal disruption to animals
and students alike, to the restricted access
and overhead power lines on site. Perhaps
with the exception of the animal residents,
however, these are all
challenges we are well
used to dealing with.
As a local employer
ourselves, we are excited
about the prospect of
having more well-trained
individuals entering the
construction workplace
in East Anglia.”
Reaping more space
for Morrison
Chalcroft has just commenced work on a
new cold storage extension and modifications
to an existing food processing facility for
Wm Morrison Supermarkets plc at its
Farmers Boy Deeside site, which is due
for completion in early 2016.
Homing in on
new A11 services
Chalcroft is nearing completion of a new
roadside rest area for Pigeon Holdings
Limited at the Fiveways Roundabout off the
A11 at Barton Mills, Suffolk. Work includes
construction of a new petrol filling station
let to Shell and new McDonald’s Restaurant
and Drive-Thru, including external works,
landscaping and car parking.
Special Projects team
navigates challenging
for Thales UK
Our most recent Special Projects completion
took place in the picturesque surroundings
of the Berry Head National Nature Reserve
near Torbay in Devon. An aircraft navigational
beacon, first installed in the 1980s and owned
by NATS (National Air Traffic Services), was
in need of refurbishment and as a main
contractor to Thales UK, Chalcroft Special
Projects were awarded the work.
The scope of the project included the installation
of a new duct to the FFM (far field monitor) tower
plus a new roof covering, installation and testing
of an earthing system and electrical equipment.
While on site, our Special Projects team also
upgraded the heating and ventilation to the
beacon and general refurbishments around
the site. As Principal Contractor, we were also
responsible for managing other sub-contractors
on site and ensuring compliance with health
and safety regulations was not compromised
– a challenge when multiple contractors were
working on conflicting tasks in a small area.
Additionally, as the beacon lies in a protected
nature reserve, work had to be planned
sensitively to avoid disruption to local wildlife.
Ray Jones, Thales Principal Engineer Airfield Systems, commented: “Chalcroft
Special Projects has provided excellent
support to us with our multi-site installation
and refurbishment project. Chalcroft’s
responsiveness, proactivity and flexibility of
approach both on-site and in the design phase
has been excellent. Additionally, the team’s
ability to devise cost-effective solutions has
validated our decision in choosing Chalcroft as
a key supplier in this important UK Air Traffic
Management programme.”
With an experienced understanding of security
critical sectors including communications and
energy supply, Chalcroft’s Special Projects
team is well equipped to provide engineering,
design and management expertise to
construction projects.
For further information on our specialist
capabilities and past projects, take a look at
Going against the drain
Raising the stakes
for Sue Ryder
A recent drainage project undertaken by
Chalcroft’s Small Works team has brought
Corby-based Food Utopia up to date with
the latest regulations to guarantee the
highest levels of hygiene. The six-week project
focused on altering the drain infrastructure and
installing new drains, working in both low-care
and high-care areas.
All three Chalcroft offices recently came
together for a party night where staff
placed their bets at a charity casino to
raise £1,120 for Sue Ryder Thorpe Hall
Hospice in Peterborough. The hospice
provides palliative care for adults with active,
progressive and advanced illnesses, and the
money raised by Chalcroft will go towards
their appeal to raise £6,000,000 for a new
purpose-designed hospice building.
Rob Copeman, Chalcroft Small Works
Manager, explained: “As this project took place
in a live food processing facility, we had to be
mindful of production demands at all times to
minimise disruption.
This included working through the night on many occasions to
make sure production areas could be cleaned in plenty of time
for use the next day. Additionally, space was often restricted,
involving working in a corridor only 1.4m wide. The drain
passed beneath at a depth of 1.5m, and so to maintain a
hygienic environment, we used advanced electrical diggers
to eliminate fumes and other emissions. Our expertise in food
processing and high-care environments ensured the project
was completed to the highest levels of hygiene and allowed
Food Utopia to meet customer demands with no disruption.”
Food Utopia Ltd is the coming together of Solway Foods
and Avana Bakeries, for whom Chalcroft has managed
previous construction projects.
Caroline Rodwell (HR Assistant, far right) and
Georgina Clark (Group HR Manager) are pictured
presenting the cheque to Jo Marriott, Head of
Fundraising at the hospice (left).
Hamlin Way
The Narrows
King’s Lynn
PE30 4NG
First Floor
6270 Bishops Court
Birmingham Business Park
B37 7YB
11 Goodwood Road
Keytec 7 Business Park
WR10 2JL
t: 01553 776543
t: 0121 227 5001
t: 01386 561965